US20200373882A1 - Solar module mounting bracket assemblies - Google Patents
Solar module mounting bracket assemblies Download PDFInfo
- Publication number
- US20200373882A1 US20200373882A1 US16/991,585 US202016991585A US2020373882A1 US 20200373882 A1 US20200373882 A1 US 20200373882A1 US 202016991585 A US202016991585 A US 202016991585A US 2020373882 A1 US2020373882 A1 US 2020373882A1
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- pair
- rail
- braces
- mounting bracket
- end portion
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Images
Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S30/00—Structural details of PV modules other than those related to light conversion
- H02S30/20—Collapsible or foldable PV modules
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/10—Arrangement of stationary mountings or supports for solar heat collector modules extending in directions away from a supporting surface
- F24S25/13—Profile arrangements, e.g. trusses
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
- F24S25/63—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing modules or their peripheral frames to supporting elements
- F24S25/634—Clamps; Clips
- F24S25/636—Clamps; Clips clamping by screw-threaded elements
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/70—Arrangement of stationary mountings or supports for solar heat collector modules with means for adjusting the final position or orientation of supporting elements in relation to each other or to a mounting surface; with means for compensating mounting tolerances
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S30/00—Arrangements for moving or orienting solar heat collector modules
- F24S30/40—Arrangements for moving or orienting solar heat collector modules for rotary movement
- F24S30/42—Arrangements for moving or orienting solar heat collector modules for rotary movement with only one rotation axis
- F24S30/425—Horizontal axis
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S20/00—Supporting structures for PV modules
- H02S20/30—Supporting structures being movable or adjustable, e.g. for angle adjustment
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S30/00—Structural details of PV modules other than those related to light conversion
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S30/00—Structural details of PV modules other than those related to light conversion
- H02S30/10—Frame structures
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S2025/01—Special support components; Methods of use
- F24S2025/012—Foldable support elements
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
- F24S2025/6003—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules by clamping
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S2025/80—Special profiles
- F24S2025/804—U-, C- or O-shaped; Hat profiles
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
- F24S25/63—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing modules or their peripheral frames to supporting elements
- F24S25/634—Clamps; Clips
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
- F24S25/65—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for coupling adjacent supporting elements, e.g. for connecting profiles together
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/40—Solar thermal energy, e.g. solar towers
- Y02E10/47—Mountings or tracking
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- the present disclosure relates generally to mounting brackets. More specifically, the present disclosure relates to mounting brackets for coupling solar modules to a framework.
- Solar mounting systems are provided to support and couple an array of one or more photovoltaic (“PV”) modules to a framework, such as, for example, a plurality of parallel-oriented, rotatable torque tubes.
- the solar mounting systems are designed to maintain the PV modules in a fixed position relative to the torque tube while the torque tube is rotating during solar tracking.
- Solar mounting systems can add significant cost to a solar power system for at least two reasons. First, the components themselves are expensive to manufacture, ship, and install. Second, installation and operation can be expensive because they require time and skilled operators to conduct quality control measures in the field. Therefore, there is a need for PV mounting systems that are easier and cheaper to package, ship, and install.
- a solar module mounting bracket assembly in one aspect of the present disclosure, includes a rail configured to support a solar module thereon, and a pair of braces each having a first end portion movably coupled to the rail.
- the braces are movable relative to the rail between a collapsed configuration and an expanded configuration. In the expanded configuration, the braces cooperatively define a channel dimensioned for receipt of a frame member.
- the braces may be parallel with the rail in the collapsed configuration, and perpendicular to the rail in the expanded configuration.
- the solar module mounting bracket assembly may assume a substantially linear shape when the braces are in the collapsed configuration. In further aspects, the solar module mounting bracket assembly may assume a substantially triangular shape when the braces are in the expanded configuration.
- the solar module mounting bracket assembly may further include a fastener configured to attach to a second end portion of each of the braces to fix the braces in the expanded configuration.
- the solar module mounting bracket assembly may further include a pair of truss arms.
- Each of the truss arms may include a first end portion movably coupled to a respective second end portion of the pair of braces, and a second end portion slidably coupled to a respective first and second end portion of the rail.
- the truss arms may be configured to move relative to the rail and the braces between a collapsed configuration and an expanded configuration. In the collapsed configuration, the truss arms may be parallel with the rail and the pair of braces, and in expanded configuration, the truss arms may extend perpendicularly relative to the rail.
- each of the truss arms may be configured to slide away from a central portion of the rail as the pair of truss arms move toward the collapsed configuration.
- each of the truss arms may move along the rail from an inward position to an outward position. In the inward position, the truss arms may assume the expanded configuration, and in the outward position, the truss arms may assume the collapsed configuration.
- each of the first and second end portions of the rail may define a track through which the respective second end portion of the truss arms slides.
- the solar module mounting bracket assembly may further include a fastener assembly coupled to the second end portion of a first of the truss arms.
- the fastener assembly may be configured to selectively fix the second end portion of the first truss arm in a position on the track of the rail.
- the fastener assembly may include a pair of washers disposed on opposite sides of the rail, and a fastener coupling the pair of washers to one another.
- the fastener may be configured to adjust a distance between the washers.
- At least one of the washers has a pair of first and second tabs extending therefrom. The first and second tabs may be configured for receipt in a corresponding slot defined in the rail.
- the first washer may further include a third tab extending therefrom.
- the third tab may be disposed in the track of the rail to guide the fastener assembly through the track.
- the solar module mounting bracket assembly may further include a protuberance protruding downwardly relative to an underside of the rail.
- the protuberance may extend into the channel defined by the braces when the braces are in the expanded configuration.
- each of the braces may have a concave inner surface, such that the channel cooperatively defined by the first and second braces has a circular shape.
- the solar module mounting bracket assembly may further include a plurality of coupling devices disposed on an upper side of the rail.
- the coupling devices may be configured to fix a solar module to the rail.
- a PV module mounting bracket assembly includes a rail, a pair of braces, a fastener, and a pair of truss arms.
- the rail is configured to support a PV module thereon and has a first end portion, a central portion, and a second end portion.
- Each of the braces includes a first end portion movably coupled to the central portion of the rail, and a second end portion.
- the braces are movable relative to the rail between a collapsed configuration and an expanded configuration. In the collapsed configuration, the braces are parallel with the rail, and in the expanded configuration, the braces are perpendicular to the rail and cooperatively define a channel dimensioned for receipt of a frame member.
- the fastener is configured to attach to the second end portion of each of the braces to fix the braces in the expanded configuration.
- Each of the truss arms includes a first end portion coupled to the respective second end portion of the pair of braces, and a second end portion slidably coupled to the respective first and second end portions of the rail.
- parallel and perpendicular are understood to include relative configurations that are substantially parallel and substantially perpendicular up to about + or ⁇ 30 degrees from true parallel and true perpendicular.
- FIG. 1 is a top view of a solar power system in accordance with an exemplary embodiment of the present disclosure
- FIG. 2A is a perspective view, with parts separated, of an exemplary embodiment of a solar modular mounting bracket assembly of the solar power system of FIG. 1 ;
- FIG. 2B is a top, perspective view of an alternative embodiment of a coupling device for coupling a solar module to a rail;
- FIG. 2C is a bottom, perspective view of the coupling device of FIG. 2B ;
- FIG. 3 is an enlarged side view of the mounting bracket assembly of FIG. 2A shown in an expanded or in-use configuration
- FIG. 4 is an enlarged side view of the mounting bracket assembly of FIG. 2A shown in a collapsed or shipping configuration
- FIG. 5 is a side view, with parts separated, of the mounting bracket assembly of FIG. 2A shown in the expanded configuration
- FIG. 5A is a top, perspective view of an alternative embodiment of a coupling nut illustrated in an attached state and a detached state;
- FIG. 6 is a side view of the mounting bracket assembly of FIG. 2A shown in the collapsed configuration
- FIG. 7A is an enlarged view of the area of detail designated “ 7 A” in FIG. 5 , illustrating a fastener assembly disposed in an inward position relative to a rail of the mounting bracket assembly;
- FIG. 7B is a cross-section, taken along line “ 7 B” in FIG. 7A , of the fastener assembly coupled to the rail of the mounting bracket assembly;
- FIG. 8A is an enlarged view of the area of detail designated “ 8 A” in FIG. 6 , illustrating the fastener assembly disposed in an outward position relative to the rail of the mounting bracket assembly;
- FIG. 8B is a cross-section, taken alone line “ 8 B” in FIG. 8A , of the fastener assembly coupled to the rail of the mounting bracket assembly;
- FIG. 9A is top perspective view of the mounting bracket assembly shown in the collapsed configuration and supported on a torque tube of the solar power system of FIG. 1 ;
- FIG. 9B is top perspective view of the mounting bracket assembly shown in the expanded configuration and supported on the torque tube of the solar power system of FIG. 1 ;
- FIG. 9C is an enlarged side view of the mounting bracket assembly shown secured to the torque tube
- FIG. 9D is a bottom, perspective view of the mounting bracket assembly attached to an underside of an alternative embodiment of a solar module having a wire management clip;
- FIG. 9E is a top, perspective view of the solar module of FIG. 9D shown in phantom, thereby revealing the wire management clip;
- FIG. 10 is a side cross-sectional view of an alternative embodiment of a rail of the mounting bracket assembly.
- solar module refers to any suitable solar panel or array of solar panels that convert energy from the sun into usable energy.
- the present disclosure in accordance with various example embodiments thereof, relates to a mounting bracket assembly for coupling one or more solar modules (e.g., PV modules) to a framework.
- the mounting bracket assembly has a rail for affixing the one or more PV modules thereon, and a pair of braces pivotably coupled to the rail.
- the braces are movable relative to the rail from a collapsed configuration to an expanded configuration.
- the collapsed configuration reduces the overall footprint of the mounting bracket assembly, thereby reducing packaging and shipping costs.
- the braces grasp the framework (e.g., a torque tube) to fix the mounting bracket assembly and, in turn, the one or more PV modules, to the framework.
- the mounting bracket assembly may also include a pair of truss arms that couple to the respective braces to provide support for the braces.
- the truss arms are configured to collapse with the braces.
- a solar power system 10 is illustrated and generally includes an array of solar modules 12 (e.g., PV modules), a framework, such as, for example, a torque tube 14 , and a mounting bracket assembly 100 for coupling the array of PV modules 12 to the torque tube 14 .
- Each of the mounting bracket assemblies 100 may be oriented perpendicularly relative to the torque tube 14 and extend crosswise under each of the PV modules 12 .
- the torque tube 14 is rotatable about an axis to adjust an angular orientation of the PV modules 12 relative to the sun.
- the system 10 may include more than one torque tube 14 , connected end to end and wherein each set of end to end connected torque tubes 14 are arranged in a parallel orientation with one another.
- Each torque tube 14 may have an array of PV modules 12 affixed thereto via a plurality of mounting bracket assemblies 100 .
- two mounting bracket assemblies 100 may be utilized for coupling four PV modules 12 to the torque tube 14 . It is contemplated that any suitable number of mounting bracket assemblies 100 are employed to affix any suitable number of PV modules 12 to the torque tube 14 .
- an exemplary mounting bracket assembly 100 is illustrated and generally includes an elongated rail 102 , a pair of first and second braces 104 , 106 movably coupled to the rail 102 , and a pair of first and second truss arms 108 , 110 for supporting the first and second braces 104 , 106 relative to the rail 102 .
- the rail 102 has a generally rectangular shape and a U-shaped cross-sectional configuration.
- the rail 102 includes an upper wall 112 , and a pair of lateral side walls 114 , 116 extending perpendicularly downward from the upper wall 112 , thus forming a U-shaped channel 118 in an underside of the rail 102 .
- the rail 102 has opposing first and second end portions 102 a , 102 b and defines a longitudinal axis “X” therebetween. It is contemplated that the rail 102 may assume any suitable shape, such as square, rounded, or the like.
- the rail 102 has a plurality of coupling devices 120 disposed on the upper wall 112 of the rail 102 .
- the coupling devices 120 are spaced from one another along the longitudinal axis “X” of the rail 102 .
- Each of the coupling devices 120 includes a support member 122 that is fixed to the upper wall 112 of the rail 102 , and a clip 124 detachably coupled to the support member 122 .
- the support member 122 may be fabricated from a relatively pliable material, such as, for example, an elastomer, to provide a forgiving surface on which a PV module 12 is to be seated.
- the support member 122 defines an opening 126 therethrough dimensioned for receipt of a shroud 128 .
- the shroud 128 extends upwardly from the upper wall 112 of the rail 102 and is fixed thereto.
- the clip 124 of the coupling device 120 includes a plate member 130 and a fastener 132 (e.g., a screw) extending downwardly therefrom.
- the fastener 132 of the clip 124 is configured to be coupled (e.g., via threaded engagement or friction-fit engagement) with the shroud 128 .
- FIG. 2B depicts a further aspect of the present disclosure related to the coupling device 120 .
- this aspect employs a pad 125 which supports the support member 122 and is received on the shroud 128 to attach the pad 125 to the rail 102 .
- the pad 125 may have a plurality of tabs 127 configured to clip the pad 125 to the upper wall 112 of the rail 102 .
- the pad 125 may have any suitable fastening mechanism for attaching to the rail 102 , such as, for example, adhesives.
- the pad 125 allows for reduction of the width of the rail 102 while providing an adequate bearing surface for solar modules 12 .
- the pad 125 may be formed of sheet metal and placed under the support member 122 .
- FIG. 2C depicts a bottom perspective view of the coupling device 120 attached to a rail 102 and showing the pad 125 and support member 122 extending over the edges of the rail 102 .
- the fastener 132 of the clip 124 is positioned through the opening 126 of the support member 122 and threadedly coupled to a threaded inner surface of the shroud 128 .
- the fastener 132 of the clip 124 may be fastened to the shroud 128 via a friction-fit engagement.
- the plate member 130 of the clip 124 is approximated towards the support member 122 (e.g., via rotation of the fastener 132 ) until the PV modules 12 are captured between the plate member 130 of the clip 124 and the support member 122 .
- the rail 102 may also have coupling devices in the form of flexible, hook-shaped members 134 disposed on opposing first and second end portions 102 a , 102 b of the rail 102 .
- the hook-shaped members 134 are configured to snap over an end of a PV module 12 to resist movement of the PV module 12 along the longitudinal axis “X” of the rail 102 .
- the first end portion 102 a of the rail 102 defines a first pair of linear tracks 136 in the opposing lateral side walls 114 , 116 of the rail 102 (only the track 136 in the first side wall 114 is illustrated in FIG. 2A ).
- the second end portion 102 b of the rail 102 defines a second pair of linear tracks 138 in the opposing lateral side walls 114 , 116 of the rail 102 (only the track 138 in the first side wall 114 is illustrated in FIG. 2A ).
- the tracks 136 , 138 may be curved or assume any other suitable shape.
- the first pair of tracks 136 permits for the slidable coupling of the first truss arm 108 to the rail 102
- the second pair of tracks 138 permits for the slidable coupling of the second truss arm 110 to the rail 102 .
- the rail 102 has a center portion 102 c disposed between the first and second end portions 102 a , 102 b of the rail 102 .
- the center portion 102 c of the rail 102 may have an insert 140 disposed within the channel 118 of the rail 102 and between the pair of braces 104 , 106 .
- the insert 140 has a concave inner surface 142 and a protuberance 144 extending downwardly from the inner surface 142 thereof.
- the protuberance 144 may have a rounded configuration (e.g., dome-shaped) and be fabricated from a pliable material, such as, for example, an elastomer.
- the protuberance 144 may be fabricated from any suitable material, such as, for example, a metal.
- the protuberance 144 is configured to enhance the frictional engagement between the mounting bracket assembly 100 and the torque tube ( FIG. 1 ) when the torque tube 100 is captured between the pair of braces 104 , 106 , as will be described.
- each of the first and second braces 104 , 106 has a first end portion 104 a , 106 a and a second end portion 104 b , 106 b .
- the first end portion 104 a , 106 a of each of the braces 104 , 106 is coupled to the center portion 102 c of the rail via a fastener, such as, for example, a nut and bolt assembly.
- the first end portion 104 a , 106 a of the braces 104 , 106 is pivotable relative to the rail 102 between an in-use or expanded configuration, as shown in FIG. 3 , and a shipping or collapsed configuration, as shown in FIG. 4 .
- the braces 104 , 106 are disposed in perpendicular relation to the longitudinal axis “X” of the rail 102 .
- the braces 104 , 106 are coaxial with the longitudinal axis “X” of the rail 102 , whereby the mounting bracket assembly 100 has a substantially reduced overall profile.
- the braces 104 , 106 may each have a concave inner surface 146 , 148 , respectively.
- the concave inner surfaces 146 of the braces 104 , 106 and the concave inner surface 142 of the insert 140 cooperatively define a circular channel 150 dimensioned for receipt of the torque tube 14 ( FIG. 1 ).
- the braces 104 , 106 each have a generally U-shaped transverse cross-sectional configuration and define a longitudinally-extending U-shaped channel 152 , 154 , respectively.
- the U-shaped channel 152 , 154 of each of the braces 104 , 106 is configured to receive the lateral side walls 114 , 116 of the rail 102 upon the braces 104 , 106 moving toward the collapsed configuration.
- the mounting bracket assembly 100 further includes a main fastener 156 , such as, for example, a nut 156 a and a bolt 156 b , interconnecting the second portions 104 b , 106 b of the first and second braces 104 , 106 .
- the main fastener 156 is configured to extend through an opening 158 , 160 ( FIG. 4 ) defined in the respective second end portions 104 b , 106 b of the braces 104 , 106 .
- the main fastener 156 is configured to selectively lock the braces 104 , 106 in the expanded configuration and close the circular channel 150 .
- An approximation of the nut 156 a and bolt 156 b drives the second end portions 104 b , 106 b of the braces 104 , 106 closer to one another to constrict the circular channel 150 about the torque tube 14 .
- a nut 157 that may be used with the present disclosure.
- the nut 157 is a break-away sheer nut and may be used in place of nut 156 a .
- the break-away sheer nut 157 may be pre-installed on the bolt 156 b .
- To install to a proper torque setting, all that an installer must do is apply torque to the nut 157 until the hex head 157 a separates from the body 157 b .
- the stress-concentration of the break-away sheer nut 157 can be sized such that separation of the hex head 157 a occurs upon application of a predetermined pressure to the bolt 156 a that will hold the bracket assembly 100 on the torque tube 14 .
- the hex head 157 a can then be discarded, but importantly for field installations, proper torque application can be assured without requiring any special tools or fear of over-torqueing of the nut 157 a that could result in damage to the torque tube 14 or other components.
- the mounting bracket assembly 100 further includes a pair of first and second truss arms 108 , 110 that provide support for the braces 104 , 106 when in the expanded configuration.
- Each of the truss arms 108 , 110 has a first end portion 108 a , 110 a and a second end portion 108 b , 110 b .
- the first end portion 108 a , 110 a of each of the truss arms 108 , 110 is coupled to the respective second end portion 104 b , 106 b of the braces 104 , 106 via a fastener, such as, for example, a nut and bolt assembly.
- the first end portion 108 a , 110 a of each of the truss arms 108 , 110 may be disposed within the U-shaped channel 152 , 154 of the respective brace 104 , 106 .
- each of the truss arms 108 , 110 is pivotable relative to the respective brace 104 , 106 between an in-use or expanded configuration, as shown in FIG. 3 , and a shipping or collapsed configuration, as shown in FIG. 4 .
- the truss arms 108 , 110 are disposed in oblique or transverse relation to the longitudinal axis “X” of the rail 102 and the braces 104 , 106 , thus giving the mounting bracket assembly 100 a generally triangular shape or A-shape.
- the truss arms 108 , 110 are disposed in parallel relation to the rail 102 and the braces 104 , 106 , thus giving the mounting bracket assembly 100 a substantially linear configuration.
- the second end portion 108 b , 110 b of each of the truss arms 108 , 110 is slidably coupled to the respective first and second end portions 102 a , 102 b of the rail 102 .
- the second end portion 108 b , 110 b of each of the truss arms 108 , 110 is configured to slide along the respective track 136 , 138 of the rail 102 between an inward position ( FIG. 5 ), and an outward position ( FIG. 6 ).
- the mounting bracket assembly 100 further includes a pair of first and second fastener assemblies 170 , 172 .
- the first fastener assembly 170 slidably couples the second end portion 108 b of the first truss arm 108 to the tracks 136 of the first end portion 102 a of the rail 100
- the second fastener assembly 172 slidably couples the second end portion 110 b of the second truss arm 110 to the tracks 138 of the second end portion 102 b of the rail 100 .
- the fastener assemblies 170 , 172 are configured to selectively lock the second end portion 108 b , 110 b of each of the respective truss arms 108 , 110 in the inward position. Due to the first and second fastener assemblies 170 , 172 being the same or substantially similar, only the first fastener assembly 170 will be described in detail herein.
- the first fastener assembly 170 includes a pair of washers 174 , 176 and a fastener 178 , such as, for example, a nut and a bolt coupling the pair of washers 174 , 176 to one another.
- the washers 174 , 176 are disposed on the respective first and second lateral sidewalls 114 , 116 of the rail 102 , and the fastener 178 extends transversely through the pair of tracks 136 in the first and second lateral sidewalls 114 , 116 of the first end portion 102 a of the rail 102 .
- the fastener 178 also extends through the second end portion 108 b of the first truss arm 108 , thereby slidably coupling the second end portion 108 b of the truss arm 108 to the first end portion 102 a of the rail 102 .
- the washers 174 , 176 of the fastener assembly 170 each include a pair of first and second flanges or tabs 174 a , 174 b and 176 a , 176 b extending perpendicularly from an outer periphery thereof.
- the first and second tabs 174 a , 174 b and 176 a , 176 b of each of the washers 174 , 176 are disposed on opposite sides of the respective washer 174 , 176 .
- the tabs 174 a , 174 b and 176 a , 176 b of the washers 174 , 176 may have a squared configuration and be dimensioned for receipt in a pair of corresponding slots 180 , 180 b ( FIG. 8A ) defined in the first end portion 102 a of the rail 102 .
- the slots 180 a , 180 b are disposed on opposite longitudinal sides of the track 136 and at an inward end of the track 136 .
- the tabs 174 a , 174 b and 176 a , 176 b of the washers 174 , 176 are aligned with the corresponding slots 180 a , 180 b in the first end portion 102 a of the rail 102 .
- An actuation of the fastener 178 drives an approximation of the washers 174 , 176 , whereby the tabs 174 a , 174 b of the washers 174 , 176 are received in the corresponding slots 180 a , 180 b in the rail 102 to fix or lock the fastener assembly 170 to the rail 102 and, in turn, lock the second end portion 108 b of the first truss arm 108 in the inward position.
- the washers 174 , 176 may further include a third flange or tab 174 c extending perpendicularly from the outer periphery thereof.
- the third tab 174 c is received in the track 136 of the first end portion 102 a of the rail 102 to guide the fastener assembly 170 along the track 136 .
- a compression tube 179 ( FIG. 7B ) may be provided that extends between the walls 114 , 116 of the rail 102 and which has the fastener 178 extending therethrough. The compression tube 179 prevents the walls 114 , 116 of the rail 102 from collapsing during a tightening of the fastener 178 .
- the compression tube 179 depicted in FIGS. 7B and 8B an aspect of the present disclosure relating to the capturing of the compression tube 179 in the truss arms 108 is shown. Specifically, following formation of the hole in the truss arms 108 for receiving the fastener 178 , the compression tube 179 can be placed opposite the hole, and a hydraulic press may be employed to flare the edges of the hole into the compression tube 179 , thereby pressing the edges that define the hole around and onto the inner periphery of the compression tube 179 . The result is two-fold.
- the flared hole is larger than what was originally bored in the truss arm 108 allowing for the passage of a fastener 178 that has a larger diameter than the originally formed hole.
- the second result is that the compression tube 179 is permanently captured in the truss arm 108 allowing for ease of installation in the field as the installer is no longer required to align the bore of the compression tube 179 with the holes in the truss arms 108 .
- the mounting bracket assembly 100 While in the collapsed or shipping configuration, is positioned over the torque tube 14 of the solar power system 1 ( FIG. 1 ) with the center portion 102 c of the rail 102 overlapping the torque tube 14 .
- the protuberance 144 ( FIG. 3 ) of the insert 140 abuts the outer surface of the torque tube 14 and the braces 104 , 106 are disposed on opposite sides of the torque tube 14 .
- the braces 104 , 106 of the mounting bracket assembly 100 are rotated outwardly from the rail 102 , in the direction indicted by arrow “A” in FIG. 9B , toward the expanded configuration.
- Rotation of the braces 104 , 106 causes the first end portion 108 a , 110 a of each of the truss arms 108 , 110 to rotate relative to the respective second end portions 104 b , 106 b of the braces 104 , 106 .
- a rotation of the braces 104 , 106 is continued until the inner surfaces 146 , 148 of the braces 104 , 106 capture the torque tube 14 therebetween, as shown in FIG. 9C .
- the main fastener 156 is actuated to approximate the second end portions 104 b , 106 b of the braces 104 , 106 , whereby the braces 104 , 106 exert an upwardly-oriented force on the torque tube 14 to drive the torque tube 14 into engagement with the protuberance 144 of the insert 140 .
- the concave inner surfaces 146 , 148 of the braces 104 , 106 may be coated or lined with a similar material as the protuberance 144 to strengthen the frictional engagement with the torque tube 14 .
- the second end portion 108 b , 110 b of each of the truss arms 108 , 110 is simultaneously moved to the inward position on the respective track 136 , 138 of the rail 102 .
- the first and second tabs 174 a , 174 b and 176 a , 176 b of the washers 174 , 176 of the fastener assembly 170 are disposed adjacent the slots 180 a , 180 b defined in the rail 102 .
- the fastener 178 of the fastener assembly 170 is actuated to drive an approximation of the washers 174 , 176 , whereby the tabs 174 a , 174 b and 176 a , 176 b of the washers 174 , 176 are received in the corresponding slots 180 a , 180 b in the rail 102 to fix or lock the fastener assembly 170 to the rail 102 and, in turn, lock the second end portion 108 b of the first truss arm 108 in the inward position.
- the remaining fasteners of the mounting bracket assembly 100 may be tightened to ensure that the mounting bracket assembly 100 remains fixed in the expanded or in-use configuration.
- the PV modules 12 are then secured to the rail 102 of the mounting bracket assembly 100 via the coupling devices 120 , 134 in the manner described above.
- the rail 102 may have pre-installed wire management clips 162 attached to lateral sides of the rail 102 .
- the wire management clips 162 may be axially aligned with one another and spaced along the rail 102 .
- the clips 162 may be positioned at any suitable location on the rail 102 or other components of the mounting bracket assembly 100 .
- a rail 102 having a generally C-shaped cross-section is not so limited. Rather, a variety of cross-sectional shapes may be employed without departing from the scope of the present disclosure.
- a high hat configuration as depicted in FIG. 10 can be employed.
- the high-hat rail 102 is similar to the C-shaped rail, but includes two flanges 107 a , 107 b extending perpendicularly from the channel, which provide further stability for the rail 102 .
- the flanges 107 a , 107 b may extend at any suitable angle relative to the body of the rail.
- the fasteners described herein may be any suitable fastening mechanism, including, but not limited to, adhesives, hinges, clips, ties, straps, belts, tapes and/or fabric hook-and-loop fasteners.
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Abstract
Description
- The present disclosure relates generally to mounting brackets. More specifically, the present disclosure relates to mounting brackets for coupling solar modules to a framework.
- Solar mounting systems are provided to support and couple an array of one or more photovoltaic (“PV”) modules to a framework, such as, for example, a plurality of parallel-oriented, rotatable torque tubes. The solar mounting systems are designed to maintain the PV modules in a fixed position relative to the torque tube while the torque tube is rotating during solar tracking.
- Solar mounting systems can add significant cost to a solar power system for at least two reasons. First, the components themselves are expensive to manufacture, ship, and install. Second, installation and operation can be expensive because they require time and skilled operators to conduct quality control measures in the field. Therefore, there is a need for PV mounting systems that are easier and cheaper to package, ship, and install.
- In one aspect of the present disclosure, a solar module mounting bracket assembly is provided. The solar module mounting bracket assembly includes a rail configured to support a solar module thereon, and a pair of braces each having a first end portion movably coupled to the rail. The braces are movable relative to the rail between a collapsed configuration and an expanded configuration. In the expanded configuration, the braces cooperatively define a channel dimensioned for receipt of a frame member.
- In aspects, the braces may be parallel with the rail in the collapsed configuration, and perpendicular to the rail in the expanded configuration.
- In aspects, the solar module mounting bracket assembly may assume a substantially linear shape when the braces are in the collapsed configuration. In further aspects, the solar module mounting bracket assembly may assume a substantially triangular shape when the braces are in the expanded configuration.
- In aspects, the solar module mounting bracket assembly may further include a fastener configured to attach to a second end portion of each of the braces to fix the braces in the expanded configuration.
- In aspects, the solar module mounting bracket assembly may further include a pair of truss arms. Each of the truss arms may include a first end portion movably coupled to a respective second end portion of the pair of braces, and a second end portion slidably coupled to a respective first and second end portion of the rail.
- In aspects, the truss arms may be configured to move relative to the rail and the braces between a collapsed configuration and an expanded configuration. In the collapsed configuration, the truss arms may be parallel with the rail and the pair of braces, and in expanded configuration, the truss arms may extend perpendicularly relative to the rail.
- In aspects, the second end portion of each of the truss arms may be configured to slide away from a central portion of the rail as the pair of truss arms move toward the collapsed configuration.
- In aspects, the second end portion of each of the truss arms may move along the rail from an inward position to an outward position. In the inward position, the truss arms may assume the expanded configuration, and in the outward position, the truss arms may assume the collapsed configuration.
- In aspects, each of the first and second end portions of the rail may define a track through which the respective second end portion of the truss arms slides.
- In aspects, the solar module mounting bracket assembly may further include a fastener assembly coupled to the second end portion of a first of the truss arms. The fastener assembly may be configured to selectively fix the second end portion of the first truss arm in a position on the track of the rail.
- In aspects, the fastener assembly may include a pair of washers disposed on opposite sides of the rail, and a fastener coupling the pair of washers to one another. The fastener may be configured to adjust a distance between the washers. At least one of the washers has a pair of first and second tabs extending therefrom. The first and second tabs may be configured for receipt in a corresponding slot defined in the rail.
- In aspects, the first washer may further include a third tab extending therefrom. The third tab may be disposed in the track of the rail to guide the fastener assembly through the track.
- In aspects, the solar module mounting bracket assembly may further include a protuberance protruding downwardly relative to an underside of the rail. The protuberance may extend into the channel defined by the braces when the braces are in the expanded configuration.
- In aspects, each of the braces may have a concave inner surface, such that the channel cooperatively defined by the first and second braces has a circular shape.
- In aspects, the solar module mounting bracket assembly may further include a plurality of coupling devices disposed on an upper side of the rail. The coupling devices may be configured to fix a solar module to the rail.
- In further aspects of the present disclosure, a PV module mounting bracket assembly is provided that includes a rail, a pair of braces, a fastener, and a pair of truss arms. The rail is configured to support a PV module thereon and has a first end portion, a central portion, and a second end portion. Each of the braces includes a first end portion movably coupled to the central portion of the rail, and a second end portion. The braces are movable relative to the rail between a collapsed configuration and an expanded configuration. In the collapsed configuration, the braces are parallel with the rail, and in the expanded configuration, the braces are perpendicular to the rail and cooperatively define a channel dimensioned for receipt of a frame member. The fastener is configured to attach to the second end portion of each of the braces to fix the braces in the expanded configuration. Each of the truss arms includes a first end portion coupled to the respective second end portion of the pair of braces, and a second end portion slidably coupled to the respective first and second end portions of the rail.
- Further details, advantages, and aspects of exemplary embodiments of the present disclosure are described in more detail below with reference to the appended figures.
- As used herein, the terms parallel and perpendicular are understood to include relative configurations that are substantially parallel and substantially perpendicular up to about + or −30 degrees from true parallel and true perpendicular.
- Embodiments of the present disclosure are described herein with reference to the accompanying drawings, wherein:
-
FIG. 1 is a top view of a solar power system in accordance with an exemplary embodiment of the present disclosure; -
FIG. 2A is a perspective view, with parts separated, of an exemplary embodiment of a solar modular mounting bracket assembly of the solar power system ofFIG. 1 ; -
FIG. 2B is a top, perspective view of an alternative embodiment of a coupling device for coupling a solar module to a rail; -
FIG. 2C is a bottom, perspective view of the coupling device ofFIG. 2B ; -
FIG. 3 is an enlarged side view of the mounting bracket assembly ofFIG. 2A shown in an expanded or in-use configuration; -
FIG. 4 is an enlarged side view of the mounting bracket assembly ofFIG. 2A shown in a collapsed or shipping configuration; -
FIG. 5 is a side view, with parts separated, of the mounting bracket assembly ofFIG. 2A shown in the expanded configuration; -
FIG. 5A is a top, perspective view of an alternative embodiment of a coupling nut illustrated in an attached state and a detached state; -
FIG. 6 is a side view of the mounting bracket assembly ofFIG. 2A shown in the collapsed configuration; -
FIG. 7A is an enlarged view of the area of detail designated “7A” inFIG. 5 , illustrating a fastener assembly disposed in an inward position relative to a rail of the mounting bracket assembly; -
FIG. 7B is a cross-section, taken along line “7B” inFIG. 7A , of the fastener assembly coupled to the rail of the mounting bracket assembly; -
FIG. 8A is an enlarged view of the area of detail designated “8A” inFIG. 6 , illustrating the fastener assembly disposed in an outward position relative to the rail of the mounting bracket assembly; -
FIG. 8B is a cross-section, taken alone line “8B” inFIG. 8A , of the fastener assembly coupled to the rail of the mounting bracket assembly; -
FIG. 9A is top perspective view of the mounting bracket assembly shown in the collapsed configuration and supported on a torque tube of the solar power system ofFIG. 1 ; -
FIG. 9B is top perspective view of the mounting bracket assembly shown in the expanded configuration and supported on the torque tube of the solar power system ofFIG. 1 ; -
FIG. 9C is an enlarged side view of the mounting bracket assembly shown secured to the torque tube; -
FIG. 9D is a bottom, perspective view of the mounting bracket assembly attached to an underside of an alternative embodiment of a solar module having a wire management clip; -
FIG. 9E is a top, perspective view of the solar module ofFIG. 9D shown in phantom, thereby revealing the wire management clip; and -
FIG. 10 is a side cross-sectional view of an alternative embodiment of a rail of the mounting bracket assembly. - Embodiments of the presently disclosed solar module mounting bracket assemblies and methods of installing the same are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. As described herein, the term “solar module” refers to any suitable solar panel or array of solar panels that convert energy from the sun into usable energy.
- The present disclosure, in accordance with various example embodiments thereof, relates to a mounting bracket assembly for coupling one or more solar modules (e.g., PV modules) to a framework. The mounting bracket assembly has a rail for affixing the one or more PV modules thereon, and a pair of braces pivotably coupled to the rail. The braces are movable relative to the rail from a collapsed configuration to an expanded configuration. The collapsed configuration reduces the overall footprint of the mounting bracket assembly, thereby reducing packaging and shipping costs. In the expanded configuration, the braces grasp the framework (e.g., a torque tube) to fix the mounting bracket assembly and, in turn, the one or more PV modules, to the framework. The mounting bracket assembly may also include a pair of truss arms that couple to the respective braces to provide support for the braces. The truss arms are configured to collapse with the braces. These and further details of the mounting bracket assemblies will be described below.
- With reference to
FIG. 1 , a solar power system 10 is illustrated and generally includes an array of solar modules 12 (e.g., PV modules), a framework, such as, for example, atorque tube 14, and a mountingbracket assembly 100 for coupling the array ofPV modules 12 to thetorque tube 14. Each of the mountingbracket assemblies 100 may be oriented perpendicularly relative to thetorque tube 14 and extend crosswise under each of thePV modules 12. Thetorque tube 14 is rotatable about an axis to adjust an angular orientation of thePV modules 12 relative to the sun. - While not illustrated, the system 10 may include more than one
torque tube 14, connected end to end and wherein each set of end to end connectedtorque tubes 14 are arranged in a parallel orientation with one another. Eachtorque tube 14 may have an array ofPV modules 12 affixed thereto via a plurality of mountingbracket assemblies 100. In embodiments, two mountingbracket assemblies 100 may be utilized for coupling fourPV modules 12 to thetorque tube 14. It is contemplated that any suitable number of mountingbracket assemblies 100 are employed to affix any suitable number ofPV modules 12 to thetorque tube 14. - With reference to
FIGS. 2A-9C , an exemplarymounting bracket assembly 100 is illustrated and generally includes anelongated rail 102, a pair of first andsecond braces rail 102, and a pair of first andsecond truss arms second braces rail 102. Therail 102 has a generally rectangular shape and a U-shaped cross-sectional configuration. Therail 102 includes anupper wall 112, and a pair oflateral side walls upper wall 112, thus forming aU-shaped channel 118 in an underside of therail 102. Therail 102 has opposing first andsecond end portions rail 102 may assume any suitable shape, such as square, rounded, or the like. - With specific reference to
FIG. 2A , therail 102 has a plurality ofcoupling devices 120 disposed on theupper wall 112 of therail 102. Thecoupling devices 120 are spaced from one another along the longitudinal axis “X” of therail 102. Each of thecoupling devices 120 includes asupport member 122 that is fixed to theupper wall 112 of therail 102, and aclip 124 detachably coupled to thesupport member 122. Thesupport member 122 may be fabricated from a relatively pliable material, such as, for example, an elastomer, to provide a forgiving surface on which aPV module 12 is to be seated. Thesupport member 122 defines anopening 126 therethrough dimensioned for receipt of ashroud 128. Theshroud 128 extends upwardly from theupper wall 112 of therail 102 and is fixed thereto. Theclip 124 of thecoupling device 120 includes aplate member 130 and a fastener 132 (e.g., a screw) extending downwardly therefrom. Thefastener 132 of theclip 124 is configured to be coupled (e.g., via threaded engagement or friction-fit engagement) with theshroud 128. -
FIG. 2B depicts a further aspect of the present disclosure related to thecoupling device 120. Specifically this aspect employs apad 125 which supports thesupport member 122 and is received on theshroud 128 to attach thepad 125 to therail 102. In embodiments, thepad 125 may have a plurality oftabs 127 configured to clip thepad 125 to theupper wall 112 of therail 102. It is contemplated that thepad 125 may have any suitable fastening mechanism for attaching to therail 102, such as, for example, adhesives. Thepad 125 allows for reduction of the width of therail 102 while providing an adequate bearing surface forsolar modules 12. Thepad 125 may be formed of sheet metal and placed under thesupport member 122. The increased width of thepad 125 compared to therail 102 width allows therail 102 to provide increased support for themodule 12 while limiting the size of therail 102 and thus reduces weight and potential costs.FIG. 2C depicts a bottom perspective view of thecoupling device 120 attached to arail 102 and showing thepad 125 andsupport member 122 extending over the edges of therail 102. - During assembly, with two longitudinal sides of a pair of adjacent PV modules 12 (
FIG. 1 ) positioned on thesupport member 122 of thecoupling device 120, thefastener 132 of theclip 124 is positioned through theopening 126 of thesupport member 122 and threadedly coupled to a threaded inner surface of theshroud 128. In embodiments, thefastener 132 of theclip 124 may be fastened to theshroud 128 via a friction-fit engagement. Theplate member 130 of theclip 124 is approximated towards the support member 122 (e.g., via rotation of the fastener 132) until thePV modules 12 are captured between theplate member 130 of theclip 124 and thesupport member 122. - It is contemplated that the
rail 102 may also have coupling devices in the form of flexible, hook-shapedmembers 134 disposed on opposing first andsecond end portions rail 102. The hook-shapedmembers 134 are configured to snap over an end of aPV module 12 to resist movement of thePV module 12 along the longitudinal axis “X” of therail 102. - The
first end portion 102 a of therail 102 defines a first pair oflinear tracks 136 in the opposinglateral side walls track 136 in thefirst side wall 114 is illustrated inFIG. 2A ). Similarly, thesecond end portion 102 b of therail 102 defines a second pair oflinear tracks 138 in the opposinglateral side walls track 138 in thefirst side wall 114 is illustrated inFIG. 2A ). In embodiments, thetracks tracks 136 permits for the slidable coupling of thefirst truss arm 108 to therail 102, and the second pair oftracks 138 permits for the slidable coupling of thesecond truss arm 110 to therail 102. - As best shown in
FIGS. 3 and 4 , therail 102 has acenter portion 102 c disposed between the first andsecond end portions rail 102. Thecenter portion 102 c of therail 102 may have aninsert 140 disposed within thechannel 118 of therail 102 and between the pair ofbraces insert 140 has a concaveinner surface 142 and aprotuberance 144 extending downwardly from theinner surface 142 thereof. Theprotuberance 144 may have a rounded configuration (e.g., dome-shaped) and be fabricated from a pliable material, such as, for example, an elastomer. In some embodiments, theprotuberance 144 may be fabricated from any suitable material, such as, for example, a metal. Theprotuberance 144 is configured to enhance the frictional engagement between the mountingbracket assembly 100 and the torque tube (FIG. 1 ) when thetorque tube 100 is captured between the pair ofbraces - With reference to
FIGS. 2A-6 , each of the first andsecond braces first end portion second end portion first end portion braces center portion 102 c of the rail via a fastener, such as, for example, a nut and bolt assembly. Thefirst end portion braces rail 102 between an in-use or expanded configuration, as shown inFIG. 3 , and a shipping or collapsed configuration, as shown inFIG. 4 . In the expanded configuration, thebraces rail 102. In the collapsed configuration, thebraces rail 102, whereby the mountingbracket assembly 100 has a substantially reduced overall profile. - The
braces inner surface braces inner surfaces 146 of thebraces inner surface 142 of theinsert 140 cooperatively define acircular channel 150 dimensioned for receipt of the torque tube 14 (FIG. 1 ). Thebraces U-shaped channel U-shaped channel braces lateral side walls rail 102 upon thebraces - The mounting
bracket assembly 100 further includes amain fastener 156, such as, for example, anut 156 a and abolt 156 b, interconnecting thesecond portions second braces main fastener 156 is configured to extend through anopening 158, 160 (FIG. 4 ) defined in the respectivesecond end portions braces main fastener 156 is configured to selectively lock thebraces circular channel 150. An approximation of thenut 156 a andbolt 156 b drives thesecond end portions braces circular channel 150 about thetorque tube 14. - Depicted in
FIG. 5A is anut 157 that may be used with the present disclosure. Specifically, thenut 157 is a break-away sheer nut and may be used in place ofnut 156 a. The break-awaysheer nut 157 may be pre-installed on thebolt 156 b. To install to a proper torque setting, all that an installer must do is apply torque to thenut 157 until the hex head 157 a separates from the body 157 b. The stress-concentration of the break-awaysheer nut 157 can be sized such that separation of the hex head 157 a occurs upon application of a predetermined pressure to thebolt 156 a that will hold thebracket assembly 100 on thetorque tube 14. The hex head 157 a can then be discarded, but importantly for field installations, proper torque application can be assured without requiring any special tools or fear of over-torqueing of the nut 157 a that could result in damage to thetorque tube 14 or other components. - With continued reference to
FIGS. 2A-6 , as briefly mentioned above, the mountingbracket assembly 100 further includes a pair of first andsecond truss arms braces truss arms first end portion second end portion first end portion truss arms second end portion braces first end portion truss arms U-shaped channel respective brace - The
first end portion truss arms respective brace FIG. 3 , and a shipping or collapsed configuration, as shown inFIG. 4 . In the expanded configuration, thetruss arms rail 102 and thebraces truss arms rail 102 and thebraces - With reference to
FIGS. 2A, 5, and 6 , thesecond end portion truss arms second end portions rail 102. In particular, thesecond end portion truss arms respective track rail 102 between an inward position (FIG. 5 ), and an outward position (FIG. 6 ). When thesecond end portion truss arms truss arms braces second end portions truss arms truss arms braces - With reference to
FIGS. 5-8B , the mountingbracket assembly 100 further includes a pair of first andsecond fastener assemblies first fastener assembly 170 slidably couples thesecond end portion 108 b of thefirst truss arm 108 to thetracks 136 of thefirst end portion 102 a of therail 100, and thesecond fastener assembly 172 slidably couples thesecond end portion 110 b of thesecond truss arm 110 to thetracks 138 of thesecond end portion 102 b of therail 100. Thefastener assemblies second end portion respective truss arms second fastener assemblies first fastener assembly 170 will be described in detail herein. - With specific reference to
FIGS. 7A-8B , thefirst fastener assembly 170 includes a pair ofwashers fastener 178, such as, for example, a nut and a bolt coupling the pair ofwashers washers lateral sidewalls rail 102, and thefastener 178 extends transversely through the pair oftracks 136 in the first and secondlateral sidewalls first end portion 102 a of therail 102. Thefastener 178 also extends through thesecond end portion 108 b of thefirst truss arm 108, thereby slidably coupling thesecond end portion 108 b of thetruss arm 108 to thefirst end portion 102 a of therail 102. - The
washers fastener assembly 170 each include a pair of first and second flanges ortabs second tabs washers respective washer tabs washers corresponding slots 180, 180 b (FIG. 8A ) defined in thefirst end portion 102 a of therail 102. Theslots track 136 and at an inward end of thetrack 136. - Upon moving the
fastener assembly 170 toward the inward position, as shown inFIG. 7A , thetabs washers slots first end portion 102 a of therail 102. An actuation of thefastener 178 drives an approximation of thewashers tabs washers slots rail 102 to fix or lock thefastener assembly 170 to therail 102 and, in turn, lock thesecond end portion 108 b of thefirst truss arm 108 in the inward position. - The
washers tab 174 c extending perpendicularly from the outer periphery thereof. Thethird tab 174 c is received in thetrack 136 of thefirst end portion 102 a of therail 102 to guide thefastener assembly 170 along thetrack 136. A compression tube 179 (FIG. 7B ) may be provided that extends between thewalls rail 102 and which has thefastener 178 extending therethrough. Thecompression tube 179 prevents thewalls rail 102 from collapsing during a tightening of thefastener 178. - With respect to the
compression tubes 179 depicted inFIGS. 7B and 8B , an aspect of the present disclosure relating to the capturing of thecompression tube 179 in thetruss arms 108 is shown. Specifically, following formation of the hole in thetruss arms 108 for receiving thefastener 178, thecompression tube 179 can be placed opposite the hole, and a hydraulic press may be employed to flare the edges of the hole into thecompression tube 179, thereby pressing the edges that define the hole around and onto the inner periphery of thecompression tube 179. The result is two-fold. First, the flared hole is larger than what was originally bored in thetruss arm 108 allowing for the passage of afastener 178 that has a larger diameter than the originally formed hole. The second result is that thecompression tube 179 is permanently captured in thetruss arm 108 allowing for ease of installation in the field as the installer is no longer required to align the bore of thecompression tube 179 with the holes in thetruss arms 108. - During assembly, with reference to
FIG. 9A , the mountingbracket assembly 100, while in the collapsed or shipping configuration, is positioned over thetorque tube 14 of the solar power system 1 (FIG. 1 ) with thecenter portion 102 c of therail 102 overlapping thetorque tube 14. In this position, the protuberance 144 (FIG. 3 ) of theinsert 140 abuts the outer surface of thetorque tube 14 and thebraces torque tube 14. As shown inFIG. 9B , thebraces bracket assembly 100 are rotated outwardly from therail 102, in the direction indicted by arrow “A” inFIG. 9B , toward the expanded configuration. Rotation of thebraces first end portion truss arms second end portions braces braces inner surfaces braces torque tube 14 therebetween, as shown inFIG. 9C . - With the
torque tube 14 captured within thechannel 150 defined by theinsert 140 and thebraces main fastener 156 is actuated to approximate thesecond end portions braces braces torque tube 14 to drive thetorque tube 14 into engagement with theprotuberance 144 of theinsert 140. In embodiments, the concaveinner surfaces braces protuberance 144 to strengthen the frictional engagement with thetorque tube 14. - As described above, when the
braces second end portion truss arms respective track rail 102. With thesecond end portions truss arms second tabs washers fastener assembly 170 are disposed adjacent theslots rail 102. To fix thesecond end portion truss arms respective track fastener 178 of thefastener assembly 170 is actuated to drive an approximation of thewashers tabs washers slots rail 102 to fix or lock thefastener assembly 170 to therail 102 and, in turn, lock thesecond end portion 108 b of thefirst truss arm 108 in the inward position. - At this stage, the remaining fasteners of the mounting
bracket assembly 100 may be tightened to ensure that the mountingbracket assembly 100 remains fixed in the expanded or in-use configuration. ThePV modules 12 are then secured to therail 102 of the mountingbracket assembly 100 via thecoupling devices - Yet a further aspect of the present disclosure can be seen in
FIGS. 9D and 9E . Specifically, therail 102 may have pre-installed wire management clips 162 attached to lateral sides of therail 102. The wire management clips 162 may be axially aligned with one another and spaced along therail 102. In other embodiments, theclips 162 may be positioned at any suitable location on therail 102 or other components of the mountingbracket assembly 100. By pre-installing the wire management clips 162, installation of thesolar modules 12 and electrical connection of them is eased and made both more efficient as well as ensuring the quality of those electrical connections by having the pre-installed wire management clips 162 available to the installer. - Finally, though generally described in connection with a
rail 102 having a generally C-shaped cross-section, the present disclosure is not so limited. Rather, a variety of cross-sectional shapes may be employed without departing from the scope of the present disclosure. For example, a high hat configuration as depicted inFIG. 10 can be employed. The high-hat rail 102 is similar to the C-shaped rail, but includes two flanges 107 a, 107 b extending perpendicularly from the channel, which provide further stability for therail 102. In aspects, the flanges 107 a, 107 b may extend at any suitable angle relative to the body of the rail. - In embodiments, the fasteners described herein may be any suitable fastening mechanism, including, but not limited to, adhesives, hinges, clips, ties, straps, belts, tapes and/or fabric hook-and-loop fasteners.
- It will be understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but merely as exemplifications of various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended thereto.
Claims (20)
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US17/584,021 US11671052B2 (en) | 2018-08-29 | 2022-01-25 | Solar module mounting bracket assemblies |
US18/140,299 US20230261610A1 (en) | 2018-08-29 | 2023-04-27 | Solar module mounting bracket assemblies |
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US16/116,238 US10797635B2 (en) | 2018-08-29 | 2018-08-29 | Solar module mounting bracket assemblies |
US16/991,585 US11251748B2 (en) | 2018-08-29 | 2020-08-12 | Solar module mounting bracket assemblies |
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US17/584,021 Continuation US11671052B2 (en) | 2018-08-29 | 2022-01-25 | Solar module mounting bracket assemblies |
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US20200373882A1 true US20200373882A1 (en) | 2020-11-26 |
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US16/991,585 Active US11251748B2 (en) | 2018-08-29 | 2020-08-12 | Solar module mounting bracket assemblies |
US17/584,021 Active US11671052B2 (en) | 2018-08-29 | 2022-01-25 | Solar module mounting bracket assemblies |
US18/140,299 Pending US20230261610A1 (en) | 2018-08-29 | 2023-04-27 | Solar module mounting bracket assemblies |
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US16/116,238 Active 2038-12-17 US10797635B2 (en) | 2018-08-29 | 2018-08-29 | Solar module mounting bracket assemblies |
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US17/584,021 Active US11671052B2 (en) | 2018-08-29 | 2022-01-25 | Solar module mounting bracket assemblies |
US18/140,299 Pending US20230261610A1 (en) | 2018-08-29 | 2023-04-27 | Solar module mounting bracket assemblies |
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EP (1) | EP3844868A4 (en) |
CN (1) | CN112740544A (en) |
AU (3) | AU2019327491B2 (en) |
WO (1) | WO2020047308A1 (en) |
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US20230188086A1 (en) * | 2021-12-09 | 2023-06-15 | National Oilwell Varco, L.P. | Mounting brackets and associated methods for securing solar modules of solar arrays |
WO2023235521A1 (en) * | 2022-06-01 | 2023-12-07 | Array Technologies, Inc. | Low-profile backrail module clamp |
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-
2018
- 2018-08-29 US US16/116,238 patent/US10797635B2/en active Active
-
2019
- 2019-08-29 CN CN201980056120.4A patent/CN112740544A/en active Pending
- 2019-08-29 WO PCT/US2019/048894 patent/WO2020047308A1/en unknown
- 2019-08-29 EP EP19855184.8A patent/EP3844868A4/en active Pending
- 2019-08-29 AU AU2019327491A patent/AU2019327491B2/en active Active
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2020
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2022
- 2022-01-25 US US17/584,021 patent/US11671052B2/en active Active
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2023
- 2023-04-27 US US18/140,299 patent/US20230261610A1/en active Pending
- 2023-11-15 AU AU2023266291A patent/AU2023266291A1/en active Pending
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US20220149772A1 (en) | 2022-05-12 |
AU2022202289A1 (en) | 2022-04-28 |
WO2020047308A1 (en) | 2020-03-05 |
EP3844868A4 (en) | 2022-05-11 |
US10797635B2 (en) | 2020-10-06 |
AU2023266291A1 (en) | 2023-12-07 |
US20230261610A1 (en) | 2023-08-17 |
US11251748B2 (en) | 2022-02-15 |
US11671052B2 (en) | 2023-06-06 |
AU2022202289B2 (en) | 2023-08-31 |
US20200076360A1 (en) | 2020-03-05 |
EP3844868A1 (en) | 2021-07-07 |
AU2019327491A1 (en) | 2021-03-04 |
AU2019327491B2 (en) | 2022-03-10 |
CN112740544A (en) | 2021-04-30 |
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